Systems and methods for manufacturing reinforced weatherstrip

ABSTRACT

Methods for manufacturing fabric-reinforced weatherstrip include incorporating a fabric application step into a process for making coated substrates. In one embodiment, a strip of the fabric from a roll of material may be applied directly onto a coating after it has been applied in a coat die to a foam profile, while the coating is still in the molten state. Alternatively, a fabric application plate may be attached to an upstream side of coating die with a fabric feed channel cut into the plate. The fabric follows the channel to contact and mate with the foam profile. The fabric applicator plate may be configured so as to exert pressure on only the part of the product where the fabric is being applied. Ultrasonic welding techniques may also be employed.

CROSS-REFERENCE TO RELATED APPLICATION

This application incorporates by reference in its entirety and is acontinuation of U.S. patent application Ser. No. 11/716,397, filed Mar.9, 2007, which claims priority to and incorporates by reference hereinin its entirety U.S. Provisional Patent Application Ser. No. 60/780,991,filed on Mar. 10, 2006.

TECHNICAL FIELD

The present invention generally relates to methods, systems, andapparatus for fabricating a fabric-reinforced (clad) coated foamsubstrate, and the products manufactured by the disclosed methods,systems, and apparatus.

BACKGROUND OF THE INVENTION

Non-reinforced coated substrates may be manufactured by a number ofmethods, as described with reference to FIGS. 1-10 and in theaccompanying text. The methods and systems associated with themanufacture of non-reinforced coated substrates are also described inU.S. Pat. No. 5,192,586 to Mertinooke et al., the disclosure of whichand all references of record therein and in the reexamination proceedingthereof are incorporated by reference herein in their entireties.

In many applications, it is desirable to provide a relatively thin,outer layer or skin for a substrate, which may be a rigid or non-rigidfoam profile or other material. The substrate may include a plurality ofcomponents, some rigid and some nonrigid. The layer or skin may performa variety of functions, such as protecting the substrate from adverseexternal conditions, providing the external surface of the substrate orportions thereof with characteristics suitable for particularapplications, providing an aesthetically appealing finished product, andthe like. The outer layer or skin may also improve the tear resistanceof the substrate and enhance overall strength providing a more durableand rugged finished product. A conducting wire surrounded by aninsulating layer is one example of a substrate having an outer layerperforming such functions. One such substrate which may include an outerlayer or skin is a weatherseal or weatherstrip, embodiments of which aredescribed herein, however, the method and apparatus described herein arenot limited in this respect; indeed, it is broadly applicable where itis desired to provide an outer layer or skin for rigid and non-rigidsubstrates including, but not limited to, foams, metals, and previouslyextruded plastics.

In general, weatherseals seal joints or spaces around doors and windowsso as to inhibit infiltration of air, rain, snow, and other elements.Effective weatherseals can reduce both heating costs in winter andcooling costs in summer. Certain characteristics are desirable toproduce an effective weatherseal. First, a weatherseal should have goodcompression set resistance. Compression set resistance refers to theability of a material to resume its initial shape after being subjectedto a compressive load. Failure to resume this initial shape may resultin an uneven seal and reduce the effectiveness of the weatherseal.Second, a weatherseal should be soft and yielding, i.e., it should beeasily compressible and conform to irregular surfaces. The gaps indoors, windows and the like in which weatherseals are utilized differ insize due to construction and other factors, and a weatherseal shouldhave sufficient compressibility to conform to a wide range of gap sizes.Compressibility also ensures that a door or window, for example, can beclosed without excessive force and still compress the weathersealsufficiently to form the necessary seal.

The prior art discloses many materials which are utilized asweatherseals. U.S. Pat. Nos. 4,328,273 and 4,185,416 disclose the use ofurethane foams for a weatherseal. Commonly assigned U.S. Pat. Nos.4,898,760, 5,192,586, 5,393,796, 5,512,601, 5,607,629, 5,654,346,5,728,406, and 5,788,889, the disclosures of which are incorporatedherein by reference in their entireties, disclose the use of a lowdensity foamed thermoplastic elastomer for a weatherseal. However, theseand similar materials may have relatively high coefficients of frictionand may be easily damaged. Thus, their effectiveness and utility as aweatherseal may be reduced. These problems are magnified where theweatherseal is subjected to sliding contact or other abrasive forces;thus, a method of manufacturing a weatherstrip having reduced frictionalcharacteristics when sliding against a surface is desirable.

In order to alleviate the problems described above, an outer layer orskin is typically provided for the weatherseal. The outer layergenerally has a low coefficient of friction relative to the surface ofcontact to facilitate relative motion and may be generally flexible topermit compression of the underlying seal. The outer layer also protectsthe seal from rips and tears caused by sliding contact or other abrasiveforces. Low friction materials such as polyethylene copolymers,polyvinylchloride, and polypropylene copolymers have been utilized inthe prior art for this outer layer.

There are several disadvantages, however, associated with providingthese low friction outer layers. Attaching the outer layer to theunderlying seal may require a separate manufacturing step and increasethe labor and associated costs required to make the seal. If the outerlayer is applied as a crosshead extrusion to the weatherseal,orientation of the outer layer during “draw-down” onto the seal createslow resistance to tears along the length of the seal. Thus, an initiallysmall tear in the outer layer can propagate into a much larger tear,adversely affecting the effectiveness and utility of the weatherseal.Additionally, crosshead extrusion apparatus generally requires complexarrangements of equipment and expensive dies. These factors alsoincrease production costs.

One prior art technique provides an outer skin for a substrate bymelting a resin and placing the melted resin in a tank or pool with anentrance opening and an exit opening. The substrate is then pulled ordragged through the melted resin. The exit opening serves as a doctorblade to configure the outer layer. However, it is difficult toprecisely control the thickness of the outer layer or to selectivelycoat portions of the substrate utilizing this prior art technique. Also,it is difficult to provide an outer layer of varying thickness. Finally,the pressure and drag exerted on a non-rigid substrate such as a foam bya viscous melted resin deforms and stretches the non-rigid substrate andgenerates a low quality product.

SUMMARY OF THE INVENTION

Notwithstanding the benefits of substrates coated in accordance with theteachings of U.S. Pat. No. 5,192,586, there exists a need for morerobust coated substrates to achieve heretofore unprecedented performancecharacteristics. FIGS. 11-19 and accompanying text describe embodimentsof the present invention. The methods described in these figures may beincorporated into the methods of manufacture described in the formerfigures to produce fabric-reinforced coated substrates. The addition ofa fabric layer or other reinforcing layer may be desirable foradditional reinforcement, cushioning, or sealing. Certain fabrics havebeen elements of weatherstrip sealing products since their introductionin the 1980's, forming barriers against air and water infiltration aspart of properly applied window and door system designs. The fabrics cancontribute toward quiet operation, low friction (low operating forces),low water and air penetration, puncture resistance, tear resistance,colorability, UV resistance and long-term weatherability, chemicalresistance, and thermal adhesion to olefin thermoplastic substrates.

Fabric clad weatherstrip offers many features such as designversatility, with many skin options utilizing an extruded polymerthermoplastic vulcanizate (TPV), for similar applications. Otherperformance characteristics may also be enhanced by varying the polymergrade and the layers of polymer added to the skin layers over the foamin order to solve specific application issues; however, some prior artsolutions become cost prohibitive or unreliable to consider due to theircomplexity or raw material cost. One such challenge is the difficultycreated by applying a weatherstrip in a meeting rail or in a jamb in atilt double hung application, where lateral forces are generated on ahighly flexible seal, causing it to tear.

In one aspect of this invention, the benefits of tear resistant, lowfriction polypropylene fabric are combined with the compression setresistance of TPV foam to provide a product of superior performance,utilizing an industry-proven TPV sealing component, while providing acost effective production method of applying the fabric to the foamsubstrate. The fabric can be utilized to fully or partially encapsulatethe foam core, and the extruded coating tie layer may bond to the insideof the fabric and to the stiffener for structural integrity andstability. In various embodiments, the fabric may be applied in stripsto provide low friction areas, hinges, reinforced areas, chafe resistantareas, or color match areas in order to impart specific characteristicsto the product. The underlying extruded layer of polymer may be simply abonding material, requiring no UV protection or low frictioncharacteristics, that being provided by the exterior layer, or it may beof lower cost material to simply act as a tie layer. The fabric may havea secondary extruded layer extruded onto or along the edges to protectthem from catching and lifting with use. The secondary layer can utilizepolyethylene, TPV, thermoplastic elastomer (TPE), polyester,polypropylene, acrylonitrite butadrene styrene (ABS), polystyreneethylene butadiene styrene (SEBS), ethylene vinyl acetate (EVA), orother suitable and thermally compatible material.

The teachings of the invention can be practiced in many ways. One methodis to apply a strip of fabric from a roll of material directly onto theskin coating, immediately after the skin has been applied, in a coat diewhile the skin is still in the molten state. The fabric may bepre-heated to enhance the bonding to the skin by the use of directed hotair or a hot plate. The fabric may travel over a roller downstream ofthe die opening, the roller being adjustable to apply appropriatepressure against the molten skin to achieve a bond. An alternativemethod is to attach a die plate to the front of the coat die with achannel cut upstream of the front plate at a right angle to the product,slightly larger than the size of the fabric. The fabric follows thechannel to the freshly coated surface and attaches to the coating skinlayer immediately after the coat die plate. The fabric application platemay utilize a profile cavity configured so as to exert pressure on onlythe part of the product where the fabric is being applied, the rest ofthe area being relieved, so as not to interfere with the cooling of theremainder of the molten skin layer.

In another aspect, the invention relates to a method of applying areinforcing material to a coated substrate including a foam profile, astiffener, and a resin coating, the method including the steps ofproviding a reinforcing material application station downstream from aresin coating station, a stiffener application station and a foamprofile extruder, and applying the reinforcing material to the substrateafter application of a resin coating, while the resin has asubstantially liquid state. In an embodiment of the above aspect, thereinforcing material application station includes a pressure roller.

In another aspect, the invention relates to a method of making aweatherstrip, the method including the steps of providing a foamprofile, providing a reinforcing material, and passing at least aportion of the profile through a coating die to coat the profile with aresin, wherein the resin attaches the reinforcing material to theweatherstrip. In certain embodiments of the above aspect, the coatingsubstantially covers the reinforcing material.

In another aspect, the invention relates to a weatherstrip having: afoam profile, a coating layer disposed along at least a portion of thefoam profile, and a reinforcing material at least partially in contactwith the coating layer. In embodiments of the above aspect, thereinforcing material is disposed between the foam profile and thecoating layer. In other embodiments, the reinforcing material isdisposed on an outer surface of the coating layer, and may include astiffener.

In another aspect, the invention relates to an apparatus formanufacturing coated weatherstrip, the apparatus having a foam extruder,a stiffener roll, a coating die and coating extruder, and a puller. Incertain embodiments of the above aspect, the apparatus includes a heatsource, which may be a hot plate and/or a hot air discharge to heat thefoam after extrusion. In certain embodiments, the apparatus includes afabric applicator, which may be located at or near the outlet of thefoam extruder. In certain embodiments, the applicator may be located atthe heat source, or it may be located where the stiffener is secured tothe foam. Alternatively, the applicator may be located beyond thestiffener application location. In other embodiments, the fabricapplicator may be integral with the coating die, or may be locatedbetween the coating die and the puller.

In another aspect, the invention relates to an apparatus formanufacturing coated weatherstrip, wherein the fabric applicator forsecuring the fabric to the extruded foam is a roller, the roller beingused with an opposing roller or a support plate. In embodiments of theapparatus where a heat source is utilized, the roller and/or supportplate or roller may serve as the heat source. In certain embodiments ofthe above aspect, where the fabric is applied to the extruded foam atthe point of application of the stiffener, the apparatus may include oneor more pressure rollers. In other embodiments, the fabric applicatormay be a plate and/or a fabric applicator die. In embodiments of theabove aspect that utilize a die, the die may be attached to the coatingdie with or without a thermal break.

Accordingly, it is an object of the present invention to provide amethod and apparatus for coating a substrate which is simple andrelatively low in cost. It is another object of the present invention toprovide a method and apparatus for coating a substrate which produces aless oriented outer layer. It is still another object of the presentinvention to provide a method and apparatus for producing a substratehaving a multiple-component outer layer. It is still another object ofthe present invention to provide a method and apparatus for providing asubstrate with an outer layer of varying thickness which may beselectively applied to portions of the substrate. It is still anotherobject of the present invention to overcome the disadvantages of theprior art.

In another aspect, the invention relates to a method of making aweatherstrip having a foam profile, a resin coating, and a cover layer,the method including the steps of providing the foam profile, providingthe cover layer, and passing the cover layer and the foam profilethrough a resin coating station, wherein at least a portion of the coverlayer is coated with the resin, while the resin is in a substantiallyliquid state. In embodiments of the above aspect, the method alsoincludes the step of applying the cover layer to at least a portion ofthe foam profile. Other embodiments include the step of attaching astiffener to at least one of the foam profile and the cover layer. Incertain of those embodiments, the passing step further includes passingthe stiffener through the resin coating station, which may coat at leasta portion of the stiffener with resin. In other embodiments of the aboveaspect, the cover layer includes an edge, at last a portion of which iscoated with the resin. In still other embodiments, the cover layerincludes a coated side and a reverse side, and the reverse cover layerside is disposed proximate to the foam profile. In certain of thoseembodiments, the coated cover layer side and the resin form a bond uponcontact. Additional embodiments of the above aspect adhere at least aportion of the cover layer to at least a portion of the foam profile.Still other embodiments include the steps of providing a forming stationupstream from the resin coating station, and passing the cover layerthrough the forming station to preform the cover layer to a shapecorresponding to a shape of the foam profile.

In yet another aspect, the invention relates to a method of making aweatherstrip having a foam profile, a resin coating, and a cover layer,the method including the steps of providing a foam profile, passing thefoam profile through a resin coating station, wherein at least a portionof the foam profile is coated with the resin, while the resin is in asubstantially liquid state, and applying the cover layer to at least aportion of the foam profile. In certain embodiments of this aspect, theportion of the foam profile to which the cover layer is applied iscoated with the resin. Additional embodiments of the above methodinclude the step of attaching a stiffener to at least one of the foamprofile and the cover layer, and may include passing the stiffenerthrough the resin coating station, which may coat at least a portion ofthe stiffener with resin. Certain embodiments of the above aspectinclude the step of applying the cover layer to the foam profile priorto the passing step. In other embodiments the cover layer is applied tothe foam profile with at least one roller, which may occur while theresin is in a substantially liquid state. Certain embodiments of any ofthe above aspects may include a cover layer, wherein the cover layerforms at least one wand, and/or the cover layer may be abraded.

In other aspects, the invention relates to a weatherstrip made inaccordance with any of the above-recited methods. In another aspect, theinvention relates to a weatherstrip having a foam profile, a stiffener,and a cover layer over the foam profile attached to at least one of thefoam profile and the stiffener along longitudinal edges of the coverlayer, so as to decouple at least a portion of the cover layer from thefoam profile. In another aspect, the invention relates to a system formanufacturing weatherstrip, the system having a foam profile source, astiffener source, a cover layer source, a resin source, a device forattaching the stiffener to the foam profile, a device for at least oneof applying the cover layer to at least a portion of the resin andapplying the resin to at least a portion of the cover layer, and adevice for coating with resin at least a portion of at least one of thefoam profile and the stiffener. In still another aspect, the inventionrelates to a method of making a weatherstrip having a cover layer and atleast one of a foam profile and a stiffener, the method including thesteps of providing the cover layer, providing at least one of the foamprofile and the stiffener, applying at least a portion of the coverlayer to the at least one of the foam profile and the stiffener tocreate a combined component, and passing the combined component throughan ultrasonic welding station, thereby securing at least a portion ofthe cover layer to the at least one of the foam profile and thestiffener.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention in accordance with thedepicted embodiments and many of the attendant advantages thereof willbe readily obtained by reference to the following detailed descriptionwhen considered in connection with the accompanying drawings, in which:

FIG. 1 is a block diagram illustrating the overall operation of oneembodiment of an apparatus for manufacturing coated weatherstrip;

FIG. 2 is a plan view of a die plate in accordance with one embodimentthe coated weatherstrip manufacturing apparatus of FIG. 1;

FIG. 3 is a cross-sectional view illustrating the coating of a substrateusing the die plate of FIG. 2;

FIG. 4 illustrates a weatherseal formed in accordance with oneembodiment of the coated weatherstrip manufacturing apparatus of FIG. 1;

FIG. 5 is a plan view of a die plate in accordance with anotherembodiment of the coated weatherstrip manufacturing apparatus of FIG. 1;

FIG. 6 illustrates a glass run channel formed with the die plate of FIG.5;

FIG. 7 is a partial block diagram illustrating the operation of anotherembodiment of a coated weatherstrip manufacturing apparatus;

FIG. 8 illustrates a weatherseal formed in accordance with theembodiment of the coated weatherstrip manufacturing apparatus of FIG. 7;

FIG. 9 illustrates another weatherseal formed in accordance with anotherembodiment of the coated weatherstrip manufacturing process;

FIG. 10 is a plan view of a die plate in accordance with anotherembodiment of the coated weatherstrip manufacturing apparatus to producethe weatherseal of FIG. 9;

FIG. 11 is a schematic representation of a manufacturing apparatus inaccordance with one embodiment of present invention;

FIG. 12 is a schematic representation of a manufacturing apparatus inaccordance with another embodiment of the present invention;

FIGS. 13A-13F are block diagrams of various embodiments of fabricapplication processes suitable for use in the manufacturing apparatusdepicted in FIG. 12;

FIG. 14 is a schematic end view of one embodiment of the fabricapplicator die of FIG. 13E;

FIGS. 15A-15C are schematic side views of fabric applicators inaccordance with other embodiments of the present invention;

FIGS. 16A-16L are schematic sectional views of various embodiments offabric-clad foam weatherstrips in accordance with certain embodiments ofthe present invention;

FIG. 17 is a schematic sectional view of a fabric-clad extruded hollowbulb seal in accordance with an embodiment of the present invention;

FIGS. 18A-18D are schematic sectional views of a fabric-cladweatherstrip manufactured in accordance with alternative embodiments ofthe present invention; and

FIG. 19 is a schematic sectional view of an embodiment of a fabric-cladfoam weatherstrip manufactured utilizing ultrasonic welding.

DETAILED DESCRIPTION

FIG. 1 schematically illustrates the overall operation of one embodimentof an apparatus for manufacturing coated weatherstrip. The productproduced in this process is a weatherseal of the type shown in FIG. 4,which includes a foam body or profile with a thin skin or coating andhaving bonded thereto a stiffener which is used to attach theweatherseal to a structure, such as a door or window jamb. The stiffeneris supplied from a reel 20. The stiffener is first heated toapproximately 120°-240° F. by a hot air blower, for example, in order toslightly soften the stiffener and to facilitate the removal of twists orbends in the stiffener as it is uncoiled and subjected to longitudinaltension. The heating also increases the temperature of the stiffenerwhich permits a more secure bond to be formed with the adhesive and skinmaterial in processing steps described below.

The stiffener is then subjected to a corona treatment or other surfacetreatment method to enhance bonding of the adhesive to the stiffener andthe skin to the stiffener. Next, an adhesive is applied to thestiffener. The adhesive may be applied by a conventional hot melt systemor other methods. The adhesive may be chosen to effect secure bonding ofthe foam to the stiffener. It will be recognized by those skilled in theart that the adhesive utilized will depend on the materials to be bondedas well as the temperatures the resultant structure will experienceduring subsequent processing steps and in use as a weatherseal. In oneembodiment, effective bonding of low density SANTOPRENE® foam to apolypropylene stiffener is achieved with hot melts such as EXTREMEADHESIVES® ADT-067 or other amorphous polypropylene based hot melts, orthermoplastic rubber-based pressure sensitive hot melts. SANTOPRENE ismanufactured by Advanced Elastomer Systems, LP. EXTREME ADHESIVESADT-067 is manufactured by Adhesive Engineering & Supply, Inc. Thecharacteristics and properties of SANTOPRENE are disclosed in U.S. Pat.Nos. 4,130,535 and 4,311,628, the disclosures of which are incorporatedby reference herein in their entireties. SANTOPRENE is a thermoplasticelastomeric composition including blends of olefin rubber andthermoplastic olefin resin.

Foam is supplied from a reel 30. The foam is preferably a low densitythermoplastic elastomeric foam described in the aforementioned patents.The foam is bonded to the stiffener to which the adhesive has beenapplied at a point schematically indicated at 35. In order to secure aneffective bond, the foam may advantageously have no longitudinal tensionas it is bonded to the stiffener.

The foam-stiffener combination is then pulled through a coating die,such as die 40, where an outer layer or skin of a melted resin producedby an extruder 42 is applied. The details of the application of thisouter layer or skin are discussed below. After being pulled through thedie 40, the resultant weatherseal is cooled by a spray mist of water, awater bath, or forced air. An air wipe subsequently removes excess waterfrom the weatherseal, if necessary. The coated weatherseal passesthrough a puller 46 prior to storage or packaging. The puller 46generates the necessary force for pulling the foam-stiffener combinationthroughout the above-described operation. Generally, the puller mayproduce a line speed in ranges from about 10 to 200 feet per minute toabout 50 to 100 feet per minute. In certain embodiments, the line speedfor producing the weatherstrip is about 60-75 feet per minute; in otherembodiments, the line speed is about 75-100 feet per minute. Factorssuch as the surface area of the substrate or portions thereof which areto be coated effect the line speed and may be taken into consideration.

It is not necessary that the foam and stiffener be unwound from reels.It is possible, for example, for either the foam or stiffener or both tobe extruded in line with the apparatus of the present invention. Such anarrangement requires proper control of the various line speeds butresults in a single production line for the product.

With reference to FIG. 2, a die plate 50 of the die 40 is typicallyformed of metal and has a thickness ranging from about 0.5 to 0.75inches. These dimensions, however, will vary with the requirements ofthe particular coating process. The die plate 50 includes a resinchannel 55 formed on one side thereof. The resin channel 55 has a depthof approximately 0.25 inches. As noted with respect to die thickness,this dimension is not critical and may be varied in accordance with therequirements of a particular coating process. An opening 60 is coupledto the output of an extruder 42 shown in FIG. 1. The opening 60 admitsresin melted by the extruder 42 into the resin channel 55. Although theresin admitted to the resin channel 55 in the present embodiment isproduced by an extrusion apparatus, this is not a necessary requirement.For some materials, the application of sufficient heat will create amelt which may be forced into the die under pressure by conventionalpumping techniques. The pressure is approximately 100 pounds per squareinch (psi) and may vary between about 50 and 1000 psi depending on thecoating process. Some polymers, however, may require both heat andshearing action to produce a melt and therefore require an extrusionapparatus. Still other resins for coating a substrate, such as latextype resins, are room temperature liquids and hence do not requiremelting and may simply be forced into resin channel 55 under pressure.

The melted resin admitted to the resin channel 55 via the opening 60 isdivided into two streams by a die portion 65. The resin within the resinchannel 55 is at a pressure determined by the operating conditions ofthe extruder 42 (e.g., temperature, screw speed, temperature profile,etc.), the die configuration and the metering gap (described below).Increasing the screw speed of the extruder 42, for example, increasesthe pressure within the resin channel 55. As discussed below, thepressure within the resin channel 55 controls the thickness of thecoating layer or skin deposited on the substrate.

A die opening 70 is formed with a wall portion 75 having varying heightsor thicknesses. The illustrated die opening is configured to produce thedoor or window seal of FIG. 4. It will be recognized that the dieopening 70 may be configured to coat substrates of any shape inaccordance with the discussion below. As detailed below, the height ofthe wall portion 75 varies in accordance with the position of the wallportion in the resin channel 55 and the thickness of the outer layer orskin desired on the substrate at that point. The die plate 50 cooperateswith a face or scraper plate 90 having an opening 91 thereincorresponding to the die opening 70 and which is secured thereto in amanner to enclose the resin channel 55 as shown in FIG. 3. The gapsbetween the face plate 90 and the wall portion 75 form a metering gap 92for the resin.

The pressure within the resin channel 55 is a function of positiontherein and generally decreases with increasing distance from theopening 60 so as to generate a range of pressures within the channel 55.Therefore, in order to provide a layer of uniform thickness to asubstrate, the height (or thickness) of the wall portion 75 may bevaried such that the size (or length) of the metering gap 92 iscorrelated with the pressure at that point to generate a uniform resinflow onto all portions of the substrate. For example, the height of thewall portion at point 80 should be greater than the height of the wallportion at point 85 since the pressure on the resin at point 80 isgreater than the pressure on the resin at point 85. The decreased wallportion height at point 85 forms a larger metering gap and permits agreater volume of melted resin to flow between the face plate 90 and thewall portion to compensate for the reduced pressure and the flowcharacteristics of the material being applied. Additionally, thethickness of the wall may be varied by adjusting the length of the landon the top of the wall portion, as required for particular applications.

The size of the height of metering gap 92 varies between about 0.00 to0.2 inches in one embodiment for the door seal. The size of the meteringgap may vary depending on the requirements of particular coatingoperation. The size of the metering gap at various portions of the resinchannel may be varied to provide a uniformly thick skin or to provide askin whose thickness varies depending on position. The ability toprovide a skin of varying thickness is an advantage over techniques ofpulling a substrate through a pool of melted resin. In such techniques,the thickness of the skin is not easily controlled and may causedifferent portions of the substrate to be coated with differentthicknesses.

An optional ridge 87 illustrated in FIG. 3, is formed on an inner sideof the wall portion 75. The ridge 87 is spaced approximately 0.050 inchbelow the top of the adjacent wall portion and is approximately 0.030inch wide in one embodiment. The 0.050 inch spacing is not critical andthe ridge 87 is not necessary. Generally, if included, the spacingshould be sufficient to provide a pocket 97 of reduced pressures ascompared with the first range of pressures within resin channel 55. Thepocket 97 is thus maintained within a second pressure range, thepressures in the second pressure range being lower than pressures in therange of pressures in resin channel 55. The pressures in the secondpressure range are generally about atmospheric pressure. The ridge 87further forms a shoulder which can prevent some of the wall portion 75from contacting a substrate 101 as it is pulled through the die. It hasbeen determined that if an excessive length of wall portion 75 contactsthe substrate 101, a uniform skin may not obtained and a product of lowquality may be produced in certain instances. In some instances, theridge 87 permits the resin from the resin channel 55 to flow through themetering gap 92 into the pocket 97 at a lower pressure from where itsubsequently flows onto the substrate 101 being pulled through the dieopening 70. Thus, a low pressure thin stream of resin flows into thepocket 97. Although the resin is at high pressure in resin channel 55,the ridge 87 may form a low pressure region or a pocket 97 for applyingthe resin to the substrate 101. The application of the resin atapproximately atmospheric pressure aids in the production of a uniformskin. Testing has demonstrated, however, that neither the ridge 87 orthe pocket 97 are required to produce a high quality uniform coating.

The face plate 90 is secured to the die plate 50 by screws for example(not shown). The substrate 101 enters the die through a tapered lead 95.The tapered lead 95 ends in a contact surface or shoulder 99. Theshoulder 99 and the surface 98 serve to position the substrate 101 inthe die opening and further prevent the resin from traveling back awayfrom face or scraper plate 90. The resin coated on to the substrate isdoctored by the face plate 90 made of metal with the door seal profilecut therein to produce an outer layer 102. Thus, a low pressure, thinstream of resin is forced into the pocket 97 from all sides and as itcontacts the substrate, it is doctored.

The thickness of the skin applied to a substrate generally depends onthe line speed, the volumetric flow rate of the resin, and the doctoringby the face plate. However, assuming a constant line speed, the coatingof rigid and non-rigid substrates seems to have slightly differentmechanisms. The thickness of the skin on a non-rigid substrate such asfoam appears to be determined by the metering gap and the pressure inthe resin channel. As more material is forced through the metering gap,the non-rigid substrate is deflected or compressed more and a thickerskin is produced. If not as much material is forced through the meteringgap, the non-rigid substrate is deflected or compressed less and athinner skin is produced. The face plate does not appear to play acritical role in determining the skin thickness for non-rigid substratesor non-rigid portions of substrates. However, there is much lessdeflection with a rigid substrate and the face plate plays a moreimportant role in determining thickness by scraping or doctoring theapplied resin. In the die configuration of the above-describedembodiment, the rigid portion of the door seal passes through the dieopening at a point remote from opening 60, and consequently, the resinis at a relatively low pressure. It is important to ensure thatsufficient material is supplied to provide a skin for the rigid portion.A flow channel may be cut into the face plate to increase the resin flowat that point. In various embodiments, some or all of the resin channelmay be formed in the face plate.

Utilizing certain embodiments, it is also possible to coat only selectedportions of a substrate by providing no metering gap at particularpoints in resin channel 55. That is, at particular points, the top ofwall portion 75 abuts face plate 90 and no resin flows though. This maybe desirable in applications such as weatherseals where portions of theseal perform functions adversely affected by the application of a skin.The door seal of FIG. 4 depicts such a situation. A door seal 100includes a foam profile 105 and a stiffener or attachment device 110. Anadhesive layer 112 bonds the foam profile 105 to the stiffener 110. Thestiffener 110 includes barbs 115, which secure the door seal 100 in ajamb or the like. As noted above, the skin 107 should have a lowcoefficient of friction in order to facilitate the opening and closingof a door. However, this low friction skin 107 should not cover thebarbs 115, so that the seal can be effectively secured to the door jamb.A low friction layer covering the barbs 115 would inhibit their abilityto maintain a secure attachment. Such selective application of a skincan not be obtained by pulling or dragging the door seal through a poolof melted resin.

In certain embodiments, the applied resin may also be sufficiently hotto form a thermal bond with those portions of the substrate to becoated. In one embodiment, the SANTOPRENE foam and the polypropylenestiffener are coated with a non-foamed SANTOPRENE-blend skin. TheSANTOPRENE blend preferably consists of 750 parts of SANTOPRENE 221-64,250 parts of SANTOPRENE 223-50, 50 parts Ampacet #10061 (a slipadditive), and 80 parts of a color concentrate. The numericaldesignation following “SANTOPRENE” is a commercial product code whichdefines certain characteristics of the SANTOPRENE grade. The SANTOPRENEblend is extruded from a single screw extruder. The temperature of themelted SANTOPRENE blend should be approximately 480° F. to form athermal bond with the stiffener and the foam. The SANTOPRENE-blend skinhas a relatively low coefficient of friction, is soft and compliant, hasgood strength and has a good resistance to compression set. TheSANTOPRENE-blend skin also achieves a good thermal bond with theSANTOPRENE foam and the polypropylene stiffener.

The above-described method may be utilized with resins having a widerange of viscosities. Suitable skin materials for appropriate rigid andnon-rigid substrates (or combinations of the two) include thermoplasticpolymers such as olefinic plastic/olefinic rubber blends, partially orfully cross-linked rubber versions of the above including SANTOPRENE,polyethylene, ethylene/methacrylic acid copolymer, ethylene/ethylacrylate polymer, linear low density polyethylene polymers andcopolymerizations therewith, ethylene interpolymer/chlorinatedpolyolefin blends, ionomers (SURLYN®), polypropylene and polypropylenecopolymers, nylon, polyesters, and thermoplastic polyurethane andmixtures thereof. SURLYN is a registered trademark of DuPont. As notedabove, room temperature liquid resins such as latex emulsions compoundedfrom silicones, acrylics, polyurethanes, and natural or syntheticrubbers may also be used.

A die plate utilized to manufacture coated weatherstrip and theresulting weatherstrip is illustrated in FIGS. 5 and 6. FIG. 5illustrates a die plate generally indicated at 140. The die plate 140includes a resin channel 155 formed on one side thereof and an opening160. A die opening 170 is formed with wall portions 175 having varyingheights and having a ridge 187 formed on the inner surface thereof. Thedie portion illustrated in FIG. 5 is configured so as to produce theglass run channel 201 of FIG. 6. The glass run channel 201 includes aroll-formed metal channel 205 having semi-cylindrical foam portions 210a, 210 b, 210 c adhesively secured to inner walls 207, 208, 209respectively.

In order to coat the surfaces of foam portions 210 a, 210 b, 210 c withan outer layer 220, the glass run channel 201 is pulled through thechannel of die opening 170. Resin is forced by pressure in resin channel155 through metering gaps formed by wall portions 175 and acorresponding face plate (not shown) in a manner similar to thatdiscussed with respect to the above described embodiment.

The methods and apparatus described herein may also be utilized toprovide multiple outer layers to a substrate. Thus, with reference toFIG. 7, a substrate such as the foam-stiffener combination describedabove may be pulled through a die 340 having a liquid resin supply 345and be coated with a first outer layer. If it were desired, for example,to provide strips of a lower friction material over the first outerlayer in order to produce a low friction contact surface, thefoam-stiffener combination with the first outer layer could be pulledthrough a second die 350 having a liquid resin supply 355. This wouldgenerate the low friction strip 345 on a weatherseal 310 as illustratedin FIG. 8. For example, the first die may apply a skin utilizing theabove-referenced the SANTOPRENE blend while the second die may apply alatex skin as a low friction overcoat. The heat from SANTOPRENE cures ordries the latex. Alternatively, the second die may pump a slurry ofwater and micronized polyethylene or tetrafluorethylane powder orsilicone powder or other low friction material onto the hot SANTOPRENE.It will be apparent that this second layer may cover all or any portionof the first layer in accordance with the desired final product. It willalso be apparent that any number of layers may be provided. Embodimentsof a product utilizing a low friction layer, and systems and methods ofmanufacturing same, are described in more detail below.

Still another embodiment of the method of manufacturing coatedweatherstrip may utilize the multiple die arrangement of FIG. 7. Asubstrate such as the foam-stiffener combination described above may bepulled through the die 340 and be coated with a first outer layercovering only a selected portion thereof. The resultant combinationcould then be pulled through the die 350 and portions of the substratenot covered by the first layer could be coated with a second layercoextensive with the first layer. Thus, as shown in FIG. 9, a lowfriction strip 395 may be provided directly on a selected portion of thesubstrate with the remainder of the coated portions of the substratecovered with a layer 385 of different material.

FIG. 10 illustrates a die plate in accordance with another embodiment ofthe apparatus for manufacturing coated weatherstrip. A die plate 440 maybe utilized to provide a dual extruded skin. The die plate 440 includesresin channels 455 a and 455 b containing first and second differentresins, respectively, for coating a substrate pulled through a dieopening 470. The first resin is admitted to the resin channel 455 athrough an opening 460 a and the second resin is admitted to the resinchannel 455 b through an opening 460 b. The resin in the resin channel455 a is divided into two streams by a die portion 465. The resinchannels 455 a and 455 b are formed such that there is no mixture of thefirst and second resins in the channels. The first and second resins aremetered between a wall portion 475 and a face plate (not shown) into alow pressure pocket formed by a ridge 487 from where they are applied tothe substrate. The embodiment of FIG. 10 may be used to produce theweatherseal shown in FIG. 9.

One aspect of the weatherstrip produced in accordance with the describedmethods is that a less oriented skin is produced, i.e., the skinmolecules are not aligned to the same degree as they would be in acrosshead extrusion. The low orientation produces a skin which is strongand rubbery. The skin has uniform strength in all directions and doesnot propagate lengthwise tears. The skin is less oriented since it isnot drawn-down onto the substrate as in a typical crosshead die as inother prior art methods and systems.

In addition, a high pressure die, because of the high pressures and theresulting flow rates, requires very careful channeling to ensure thatthe pressures are balanced. The intricate channeling and the requirementof withstanding high pressures require machining and generally increaseproduction costs. The die used in one embodiment of the described systemis utilized in a relatively low pressure system which tends to balanceits own pressures and does not require intricate channeling. Lowpressure regions in the die of the disclosed apparatus may be easilycompensated for by reducing the height or thickness of the wallportions. Dies of this type are easier to make and are significantlyless expensive than conventional crosshead dies.

In one example of manufacturing coated weatherstrip, SANTOPRENE having adurometer reading of 64 was foamed in accordance with the methoddetailed in the aforementioned commonly assigned patents. A stiffener ofpolypropylene was bonded to the foam profile as shown in FIG. 1. A blendof 750 parts SANTOPRENE 221-64, 250 parts SANTOPRENE 223-50, 50 partsAmpacet, #10061, and 80 parts of a color additive was melted in a 1¼″extruder operated at 95 revolutions per minute and fed into a die of thetype shown in FIGS. 2 and 3 with the die at 480° F. The foam-stiffenercombination was pulled through the die at 50 feet per minute andsubsequently cooled.

In accordance with one embodiment of the present invention,tear-resistant, low-friction, polypropylene fabric or other cover layermay be combined with the compression set resistance of foam and acoating layer or skin to provide a product exhibiting desirable sealingand long life using a cost effective production method of applying thefabric to the foam substrate. Alternatively, a porous fabric, non-wovenfabric with or without a film layer, single layer or laminated film,metal mesh, fabric or metal cladding, reinforcing film or fabric, orwoven fabric may be utilized as the cover layer. The cover layer may bethe fabric/thermoplastic copolymer sold by Xamax Industries, Inc., underthe trade name FLOLAM®. Cover layers utilizing a non-woven polypropylenefabric with a polypropylene film or coating applied to one or both sidesof the fabric may also be utilized. Such a non-woven polypropylenecomposite is sold by Xamax Industries, Inc., under the designation QECM. Thickness of the fabric cover layer may vary from about less than 1mil to greater than 5 mil or more, depending on the particularmanufacturing process used, application, etc. Additionally, the fabriclayer may vary from about 1 oz/sq yd to about 2 oz/sq yd or more,depending on the application. In certain embodiments, the fabric coverlayer is coated with a 2 mil polypropylene film, and has a basis weightof 1.25 oz/sq yd. The application of the fabric or cover layer may beincorporated into the systems and methods described above regardingmanufacture of coated foam weatherstrip. Additionally, the terms “fabriclayer,” “cover layer,” “fabric cover layer,” “cladding,” “sheathing,”“fabric laminate,” etc., are used interchangeably herein and throughoutthis document, and use of one term or another does not in any way limitthe particular type of layer or material that may be utilized in aparticular application. In certain embodiments, the coating acts as atie layer, to permanently bond the fabric layer through combinedapplication of heat and pressure. The fabric layer can be utilized tofully or partially encapsulate the foam core. The fabric may be appliedin strips to provide low friction areas, hinges, reinforced areas, chaferesistant areas, or color match areas in order to impart specificcharacteristics to the product. The fabric layer may also be applieddirectly to or used in conjunction with substrates other than foam, suchas rigid plastic profiles, hollow extruded bulbs, etc. The underlyingextruded coating layer of polymer or other material may be usedprimarily as a bonding material, requiring little or no UV protection orlow friction characteristics. Those performance features in the productcan be provided by the fabric layer. The coating layer may be a lowercost material to act primarily as a tie layer, depending on theapplication and product exposure to the environment. The fabric layermay optionally have a secondary extruded layer, extruded onto the edgesto protect them from catching and lifting with use, utilizingpolyethylene, TPV, TPE, polypropylene, ABS, SEBS, or other suitable andthermally compatible material. Secondary coatings may be extruded ontothe surface of the fabric in order to impart further features, such asUV resistance, moisture resistance/water tightness, ultra-low frictioncoefficients, etc. Additionally, the fabric layer may be coated with afilm or adhesive to improve bonding properties with the coating.Alternatively, the fabric layer can be attached to the foam or otherportion of the substrate solely by the secondary layer at solely theedges, or partially or fully along the cross-sectional extent. Exemplaryembodiments of weatherstrip manufactured in accordance with the presentinvention are depicted in FIGS. 16A-16L, though other configurations areclearly contemplated and within the scope of the invention.

Various embodiments of the invention are contemplated. One embodiment ofa process line 750 for manufacturing fabric clad weatherstrip isdepicted in FIG. 11. This figure is described in more detail below. FIG.12 depicts a clad weatherstrip manufacturing apparatus 500; letters atvarious points along the process line 502 indicate points where thefabric strip may be applied to the foam profile (A, B), foamprofile/stiffener combination (C, D, E), or coated foamprofile/stiffener combination (F). The process line 502 is similar tothat of FIG. 1 and generally includes a reel of foam profile or a foamprofile extruder 504, a reel 506 of stiffener or a stiffener extruder,and an optional heat generating device 508 (e.g., a hot air blower 508 aor hot plate 508 b). The foam profile 510 and stiffener 512 are bondedor adhered together and drawn through a coating die 514 by a puller 516.The coating die 514 may be supplied with molten resin by a separateextruder 518. The coated foam profile/fabric/stiffener combination 520is then rolled or otherwise processed for storage, distribution, etc.Application of the fabric strip at the various points are described withreference to FIGS. 13A-13F.

FIG. 13A depicts an embodiment of an apparatus 530 that secures thefabric 532 to the foam profile 510 a distance downstream of the extruder504 after the profile 510 has expanded to substantially its final shape.The fabric 532 is applied to the profile 510 from a fabric roll 534utilizing a contoured pressure roller 536 in combination with acontoured pressure plate 538 or other roller of the appropriategeometry. The heat generated by the newly extruded foam profile 510 mayaid in adhering the fabric 532 to the profile 510. Downstream of thepressure roller 536, a stiffener (not shown) is applied to thefabric/foam combination 542.

FIG. 13B depicts another embodiment of an apparatus 550 that secures thefabric 532 to the foam profile 510 during a supplemental heat stage. Anoptional heat plate 508 b, hot air blower 508 a, corona, or otherthermal apparatus may be used to heat the extruded or unreeled foamprofile 510 to provide better adhesion of the fabric 532. Similar to theembodiment depicted in FIG. 13A, a contoured pressure roller 552 is usedin combination with a support plate 554 or roller of the appropriategeometry to adhere the fabric 532 to the profile 510. Alternatively, thehot plate 508 b may be used in place of the support plate 554 or roller.Downstream of the pressure roller 552, a stiffener (not shown) isapplied to the fabric/foam combination 542.

FIG. 13C depicts an embodiment of a fabric application apparatus 560wherein the fabric 532 and stiffener 512 are applied to the foam profile510 substantially simultaneously on the process line. Two opposingcontoured pressure rollers 562 a, 562 b may be utilized to apply the twocomponents to the profile 510. This application method may be utilizedfor profiles 510 that have a stiffener 512 secured on a side directly orgenerally opposite the fabric 532. The resulting foamprofile/fabric/stiffener combination 564 can then be passed through thecoating die.

FIG. 13D depicts an embodiment of a fabric application apparatus 570,wherein the fabric 532 is applied to the foam profile downstream fromthe stiffener application. Similar to the embodiment depicted in FIG.13A, a contoured pressure roller 572 is used in combination with asupport plate 574 or roller of the appropriate geometry to adhere thefabric 532 to the profile/stiffener combination 576. The resulting foamprofile/fabric/stiffener combination 564 can then be passed through thecoating die.

FIG. 13E depicts another embodiment of a fabric application apparatus580, wherein a fabric applicator die or plate 582 is utilized upstreamof the coating die 514 to apply the fabric 532 to the foamprofile/stiffener combination 584. The fabric applicator plate 582 maybe secured or bolted 594 to the coating die 514 with or without athermal break 586, which may be air, non-heat conductive material, orotherwise. A shaped opening 588 in the plate 582 allows the fabric 532to be formed properly to secure the fabric 532 to the foam/stiffenercombination 584. Optionally, a guide 590 may be used to ensure properforming of the fabric 532 around the foam/stiffener combination 584.After passing through the fabric applicator plate 582, thefabric/foam/stiffener combination 590 passes through the coating die514, where the exterior layer or skin is applied via the resin channel592, as described with regard to the manufacture of coated weatherstrip.The coated foam profile/fabric/stiffener combination 520 is then rolledor otherwise processed for storage, distribution, etc. Other embodimentsof fixtures or guides that may be used in place of the fabric applicatorplate 582 are described herein.

FIG. 13F depicts another embodiment of a fabric application apparatus600 wherein the fabric 532 is applied to the coated foam profile 602downstream from the coating die 514. Similar to the embodiments depictedin FIGS. 13A, 13B, and 13D, a contoured pressure roller 604, is used incombination with a support plate 606 or roller of the appropriategeometry to adhere the fabric 532 to the coated profile 602. In thisembodiment, the fabric 532 contacts the freshly coated surface andattaches to the coating layer immediately downstream of the coating die514, while the coating is still in the molten state. The coated foamprofile/fabric/stiffener combination 520 is then rolled or otherwiseprocessed for storage, distribution, etc.

FIG. 14 is an end view of one embodiment of the fabric application plate582 depicted in FIG. 13E. The plate body 610 defines a tapered,generally conical channel 588; however, different shapes arecontemplated, depending on the geometry of the profile 510 and desiredfinished weatherstrip product requirements. Additionally, a recess 614may be formed in a lower portion of the plate 582 to accommodate all ora portion of the stiffener 512. In the depicted embodiment, a bottomopening 616 of the die 582 retains the foam/stiffener combination 612 asthe channel 588 tapers from an oversized profile 588 a to a point 588 bwhere the channel 588 is approximately the same size as thefoam/stiffener combination 612. As the fabric 532 follows the taper ofthe channel 588, it is gradually formed until it achieves the desiredshape and proximity to the profile 510, at which time it may be adheredto the foam profile 510. The channel 588 is sized to accommodate boththe fabric 532 and the foam profile 510, with sufficient, gradualcurvature to properly form the fabric 532 so it may be conformed to thefoam profile 510 without undesired creasing. At the point 588 b wherethe fabric 532 meets the foam/stiffener combination 612, the channel 588is sized and configured approximately the same as the die opening in theresin channel 592 through which the foam/stiffener/fabric combination590 passes in the coat die 514 downstream. As the fabric 532 contactsthe foam profile 510, it presses against the profile 510 as it is passedthrough the coating die 514.

Additional fixtures and/or guides may be utilized either upstream ordownstream of the coating die 514 to guide or direct the fabric layerinto the desired position, orientation, and/or contour on the foamprofile. For example, FIGS. 15A-15C show several embodiments of fabricapplication stations 620 a, 620 b, 620 c for applying a fabric 532 to aprofile 510 at the entrance of a coating die 514. Additionally, thesefabric guides may be used for applying a fabric to a profile downstreamof the coating die 582. The fabric guide 622 a, 622 b, 622 c may besecured to the coating die 582, with or without a thermal break, or toany other proximate structure. Additionally, tapered or funnel-shapedguides are contemplated to gradually form the fabric to the shaperequired for the particular application. The guide can be mounted to thecoating die in the proper orientation and can include a channel orrecess to receive the fabric and orient the fabric to apply it at theproper location on the profile.

In the depicted embodiments, the fabric application stations 620 a, 620b, 620 c include a fabric guide 622 a, 622 b, 622 c that may be attacheddirectly to the coating die 582. Alternatively, the fabric guide 622 a,622 b, 622 c may be independent of the coating die 582. In FIG. 15A, oneembodiment of the fabric guide 622 a is depicted that includes a rod 624a or bar that spans a pair of armatures 626 a forming an opening throughwhich the fabric 532 can pass. The fabric 532 is routed between thearmatures 626 a and guided by the bar 624 a, which may be grooved orshaped to contour the fabric 532 to a desired configuration. Anotherfabric guide 622 b is depicted in FIG. 15B. In this embodiment, a guideplate 624 b is utilized to conform the fabric 532 to a desired shapeprior to passing the fabric 532 and foam/stiffener combination 576through the coating die 582. The plate 624 b may have an opening similarto that depicted in FIG. 14. Alternatively, the opening may utilize adifferent taper or radius of curvature to shape the fabric, as required.

FIG. 15C depicts a fabric guide 622 c having multiple rods or bars 624 cthat allow the approach angle α of the fabric to the foam/stiffenercombination 576 to be adjusted, as required for a particularapplication. Additionally, the fabric roll (not shown) may be positionedsuch that an initial approach angle of the fabric 532 relative to thefoam/stiffener combination 576 (i.e., the fabric angle θ) may beadjusted as needed to provide sufficient clearance depending on theapplication, fabric qualities, etc. Approach angles α between greaterthan 0° and less than about 90° are contemplated. For foam profileshaving a generally flat top surface, the approach angle α may be largerthan those used for contoured profiles. In one embodiment for a roundprofile, the approach angle α and the fabric angle θ are substantiallythe same, and in a range of less than about 45°. The guide 622 cfunctions to conform the fabric 532 to the shape of theprofile/stiffener combination 576. Such a configuration allows the guideto merely shape the fabric, without significantly redirecting the fabric532 from the fabric angle θ to the approach angle α, as a largedeviation between those two angles increases friction and may causeundesired creasing or breakage of the fabric 532. In one embodiment,this angle, α′, is less than about 10° from the foam/stiffenercombination. In other embodiments, the angle α′ may be less than about5°. This angle may be maintained for distances up to and above about 5feet to about 10 feet upstream of the fabric guide, to ensure a smoothtransition of the fabric onto the foam/stiffener combination. In certainembodiments, the angle is maintained for distances of about 6 feet toabout 8 feet upstream of the coating die. In other embodiments, theapproach angle y maintained for several inches upstream of the coatingdie.

FIGS. 16A-16L schematically depict cross-sections of various embodimentsof fabric-clad foam weatherstrip 630 manufactured in accordance with thepresent invention. Embodiments of weatherstrip made in accordance withthe invention may include stiffeners and foam profiles of virtually anyconfiguration. For example, generally linear and T-shaped stiffeners aredepicted in FIGS. 16A-16L, but other shapes, with or without retentionbarbs are contemplated. Similarly, cross sections of foam profiles maybe of any shape, including square, circular, L-shaped, trapezoidal,oval, triangular, etc. Additionally, hollow foam profiles may be used,as well as non-foam profiles. FIGS. 16A-16L are schematic depictions;thus, the sizes, thicknesses, etc. of the various elements are not toscale. Further, it should be understood that the various depictedelements are generally shown spaced apart for clarity; however, unlessotherwise described, the elements are in mating contact.

FIG. 16A depicts a weatherstrip 630 wherein the fabric layer 632 onlypartially covers the coating 634 and the foam profile 636. The coating634 includes portions 638 that overlap at least a portion of thestiffener 640 to provide additional attachment of the profile 636 to thestiffener 640. FIG. 16B depicts a fabric layer 632 completely coveringthe exposed foam profile 636. The edges 632 a of the fabric 632 arecovered by discrete portions 638 of the coating layer 634 to anchor thefabric 632 and prevents the fabric edges 632 a from releasing from theprofile 636. FIG. 16C depicts a fabric layer 632 completely covered bythe coating 634 of the weatherstrip 630. FIG. 16D depicts fabric 632located solely on the sides of the weatherstrip 630, above the coating634, providing reinforcement.

FIG. 16E depicts fabric 632 located on the sides of the weatherstrip 630and below the coating 634. In this embodiment, the fabric 632 providesreinforcement even in the absence of bonding of the foam profile 636 tothe fabric 632. FIG. 16F depicts a weatherstrip 630 similar to thatdepicted in FIG. 16E, but including an adhesive layer 642 adhering thefabric 632 to the foam profile 636. FIG. 16G depicts an embodiment ofweatherstrip 630 having fabric 632 located above the coating 632,similar to that depicted in FIG. 16A. The fabric 632 can be mechanicallytreated with an abrasive (e.g., a wire wheel) to scuff the fabric 632.The scuffed surface 644 of fabric 632 may provide increased cushioning,sealing thickness, an improved seal against irregular surfaces, and mayfurther reduce friction. FIG. 16H depicts a weatherstrip 630 utilizingthe coating 634 to hold the fabric 632 against the foam profile 636,without completely surrounding the foam profile 636. The fabric 632 maystill be utilized on a portion of the foam profile 636, with or withoutthe use of adhesive.

FIG. 16I depicts an embodiment of weatherstrip 630 having an irregularshape with fabric 632′, 632″ in two different locations. The fabric 632′located on the outer top curvature of the profile 636 prevents tearingof the profile 636 and reduces friction. The fabric 632″ on the insidecorner of the profile 636 may act as a hinge, whether supported alongits width by the skin 634, or free-floating. FIG. 16J depicts anembodiment of the weatherstrip 630 utilizing a ribbed or striated fabric644, which may provide additional sealing against irregular surfaces,friction resistance, etc. The ribs 644′ may be formed in the fabric 644;alternatively, ribs of low friction coating can be applied to spacedlocations on the fabric.

FIG. 16K depicts an embodiment of the weatherstrip 630 wherein a pleat646′ is present in the fabric 646 create a sealing wand 648.Alternatively or additionally, materials may also be extruded onto thefabric layer to create sealing wands or fins. FIG. 16L depicts anotherembodiment of the weatherstrip 630, where the coating layer 634partially overlaps the edges 632 a of the fabric 632. In thisembodiment, and in other embodiments where the coating does notcompletely cover the fabric, the coating layer may overlap the fabriclayer at its edges as desired for a particular application.Manufacturing tolerances may dictate the minimum required overlap, z,but overlaps of about 0.03 in. to about 0.06 in. are typical. Largeroverlaps may be desired for applications that require more robustadhesion of the fabric or where shear loading of the fabric isexperienced in use, but where complete overlap of the fabric is notrequired. In certain embodiments overlaps of up to about 0.2 in. areutilized.

Other types of seals 660 can benefit from application of a fabric layer,as depicted in FIG. 17. For example, silicone or rubber profiles 662(either solid or hollow) can have a fabric layer 664 applied thereto, asdepicted in FIG. 17. The core void 666 of the depicted hollow profile662, can be pressurized or supported on a mandrel when the fabric layer664 is applied to provide support, if desired. Additionally, the fabriccover layer may be applied to all or part of the outer surface of thebulb and/or stiffener, utilizing many of the same processes describedherein for manufacturing foam weatherstrip, modified as needed forhollow extruded bulb applications. The fabric layer may almost entirelysurround the profile 662, and may be secured only at the stiffener 668.Generally, the barbs 670 in such an embodiment remain exposed in thefinished weatherstrip. The coating layer 634 can be applied over, under,or solely along the edges of the fabric layer 664

In instances where the fabric layer is only bonded to the profile at theedges, and/or where the coating layer does not fully encapsulate thefoam profile, weatherstrip performance properties can be improved. FIGS.18A-18B depict an example of a weatherstrip 700 made in accordance withthe present invention. The weatherstrip 700 includes a stiffener 702having a barbed extension 704. A foam profile 706 is secured to thestiffener 702 along its base. A coating layer 708 is applied to andextends a distance D along the sides of the profile 706. A fabric layer710 covers the profile 706, and is secured only at its edges 712 by thecoating layer 708. FIG. 18A shows the weatherstrip 700 in a neutral orunstressed position. When a force F is applied to the top of theweatherstrip 700, as depicted in FIG. 18B, the weatherstrip 700 isdeformed. This deformation may occur as a result of a window or doorclosing against the weatherstrip 700. As the weatherstrip 700 deforms,the foam profile 706 is compressed (outline 714 shows the shape of theweatherstrip 700 prior to the application of force F). As the foamprofile 706 compresses, the fabric layer 710 separates from the profile706, forming gaps 716 between the profile 706 and the fabric 710. Infoam profiles, these gaps 716 expose an internal surface area of theprofile 706 (essentially along the entire length of the weatherstrip700), that allows for improved air movement in the weatherstrip 700,enabling faster compression at lower resistance and correspondinglyfaster recovery when the force F is removed. This feature provides forenhanced performance and sealing effectiveness. In embodiments of theweatherstrip 700 configured as depicted, the profile 706 may deflectsignificantly, without corresponding deformation in the coating 708.Some minimal spread S of the profile 706 to the sides of theweatherstrip 700 may occur, but it is generally limited to a range thatdoes not causes excessive wear on the weatherstrip 700 or individualelements.

FIGS. 18C-18D depict another weatherstrip 700′, having a stiffener 702′with a barbed extension 704′ produced in accordance with anotherembodiment of the invention. The foam profile 706′ is fully coated bythe coating layer 708′ with a fabric layer 710′ on top. As depicted,weatherstrip 700′ is dimensionally similar to weatherstrip 700 when inthe neutral position. Application of force F′ against the weatherstrip700′ is depicted in FIG. 18D. As the force F′ is applied, theweatherstrip 700′ deforms along its length. As the weatherstrip 700′deforms, the foam profile 706′ is compressed (outline 714′ shows theshape of the weatherstrip 700′ prior to the application of force F′).Unlike the weatherstrip 700 utilizing an unadhered fabric layer 710, thecoating 708′ cannot separate from the deforming foam profile 706′.Depending on the thickness and stiffness of the coating 708′, bulges 718can form on the outer surface of the weatherstrip 700′.

As known to those of ordinary skill in the art, compression loaddeflection (CLD) curves are important in determining suitability of foamweatherseals in fenestration applications. As depicted, the weatherstrip700 of FIG. 18B typically can be compressed further than theweatherstrip 700′ of FIG. 18D, under a similar load. This improvedcompression load deflection performance is, therefore, highly desirablein applications such as window and door seal applications. Further,compression set and compression force can be reduced, because the foamcan compress free of any surface constraints caused by a continuoussurface layer of coating or fabric. Weatherstrip drag or friction canalso be reduced, since the fabric layer can shift or move relative tothe underlying foam profile. Sealing can also be improved, since thefabric layer can have a tendency to widen and flatten, when the foamprofile is compressed. Sealing application that require more robustsealing, however, nonetheless can benefit from the fully encapsulatedand attached foam profile.

The process of applying fabric to the inside or outside of the skin orcoating layer of a weatherstrip utilizes any of the coated weatherstripmanufacturing processes described above. The manufacturing process mayinclude a series of thermoplastic resin extruders laid out in asequential pattern, so as to optimize the efficiency of applyingsequential components and layers of polymeric material to the product.Thermal bonding may be used advantageously in order to join thecomponents together to produce a complex weatherstrip structure in crosssectional profile, but with an infinite length. The extruder locationscan be configured to optimize the ability of a single operator to seeand monitor the controls, speeds, and output of the entire line, and tomake adjustments according to product and process requirements. The foamprofile production process rate is controlled by the conveyor speed, thestiffener rate by the first puller speed, and the coated combinedproduct by the second puller speed, thus balancing the system so thatthe output from each extruder is matched with the line's output speed.This is accomplished by a combination of tension, loop control, andextruder output. In the alternative, foam and/or stiffener componentscan be pre-extruded and stored on reels or bins and fed into the coatdie, increasing material handling and storage, but reducing size of thefloor layout for the production line.

Settings for one embodiment of a weatherstrip manufacturing apparatus(such as an embodiment of the apparatus depicted in FIG. 11) aredepicted in Table A, below. This exemplary process line utilizesextruders for the foam profile, stiffener (which may be co-extruded withbarbs), and weatherstrip coating or skin. One advantage of the processdisclosed herein is that the fabric application may occur withoutsignificant modifications to the process line settings, allowing for anefficient and cost effective change-over in production of coatedweatherstrip to the fabric-reinforced weatherstrip disclosed herein. Inthe Table, the Additive Feeder and Extruder Speeds are dial settings.The screens are utilized in the extrusion process. Dual screen systemsare used for various sizes (e.g., 14 openings/in. and 40 openings/in.).

TABLE A Process Line Settings FOAM EXTRUDER Additive Feeder: 200Profile: Zone 1: 300° F. Zone 2: 330° F. Zone 3: 350° F. Zone 4: 350° F.Zone 5: 350° F. Zone 6: 350° F. Zone 7: 345° F. Zone 8: 340° F. Clamp:365° F. Die: 365° F. Water Injection: 3.8 ml/min; Extruder Speed: 275;Conveyer Speed: 60 ft/min; Screens: 14/40 STIFFENER EXTRUDER Profile:Zone 1: 390° F. Zone 2: 440° F. Zone 3: 440° F. Die 1: 450° F. Die 2:450° F. Extruder Speed: 1000; Puller Speed: 60.4 ft/min; Screens 14/40BARB EXTRUDER Profile: Zone 1: 390° F. Zone 2: 440° F. Zone 3: 440° F.Adapter: 450° F. Die 1: 450° F. Extruder Speed: 440; Screens: 14/40COATING EXTRUDER Profile: Zone 1: 350° F. Zone 2: 400° F. Zone 3: 445°F. Die 1: 445° F. Die 2: 440° F. Die 3: 445° F. Extruder Speed: 815;Puller Speed 60.6 ft/min; Screens 14/40

The layout of the stiffener die is generally in-line with the coatingdie and hot-melt adhesive applicator, with the foam being carried intothe path of the stiffener from a right-angle approach. Likewise, thedirection of resin flow supplying the coat die is at about a 90-degreeangle from the stiffener, but other arrangements are also contemplated.For an efficient use of floor space, the coating resin extruder can beplaced parallel with the stiffener extruder with an elongated adaptorwith an “S” channel situated therein, allowing, on the inlet end, ameans of attaching the adaptor to the face of the coat extruder exitface plate by mounting screws set in a circular fashion. In oneembodiment, a pipe fitting is attached at the die end of the “S” channelwhich is in turn attached to the inlet of the coat die. By the use ofthis offset adaptor plate, the coat die is mounted offset to the coatextruder, conserving floor space and allowing a single operator to runthe line. This also allows the foam conveyor, which is required togradually cool the foam to nearly ambient surface temperature, to extendparallel to, but behind, the coat extruder, giving the operator goodvisibility and control over the foaming process. The offset adaptorplate positions the coating resin extruder away from the location wherethe fabric is applied, whether it is at the foam conveyor, before thecoating die, or after the coating die. The offset adaptor plate can befurther adapted to accommodate any changes that may be required to makeroom for the addition of guides, rollers, heaters, or the like forapplication of the fabric.

In certain applications, foam is reeled under predetermined tension andorientation, and unwound from the reel and combined with polyethylenefilm utilizing guidance and tension control methods. In theseapplications, guidance and tension control can be used to moreeffectively feed the release liner film onto the product downstream ofthe coat die. Alternatively, foam and finished product is wound ontoreels in a controlled manner, stored, and sold for use as finishedproduct. The replacement of a standard mechanical “dancer arm” method ofdriving the rotary motion of a reel-up machine with the an ultrasonicpulse generator to sense the slack loop required to maintain properreel-up tension control helps prevent damage to the foam products.

Additionally, a preheating or corona treatment stage may be used on oneor more substrates involved in the application of the fabric. Warmingplates, heat tunnels, hot air guns, and heat lamps may be used topreheat adhesive backed film, foam, and stiffener material to enhancethe bond between components of weatherstripping or other coatedproducts. Further steps of applying heated air to the stiffener in orderto dry and preheat the product to enhance the thermal adhesion may alsobe utilized. Corona treatment of film, stiffener, and foam with Coroteccorona discharge units may enhance the adhesion properties as well. Forfabric layers that are treated with an adhesive coating, a preheatingstation of the types described may be utilized prior to applying thefabric layer to the foam profile or stiffener, to ensure a satisfactorybond. Alternatively, the heat generated by the coating die itself or theextruded foam or stiffener may help secure the fabric, depending on thethermal properties of the adhesive used.

The shape of the extruded stiffener may also be controlled by utilizinga single brass block with the shape of the product cut along the lengthof the upper surface. This block may be fitted into a holder attached toa vacuum apparatus to produce stiffener profiles more precisely thanhave previously been achieved. A series of slots may be cut by wire EDMin the sizer block so as to hold the product lightly against the uppersurface of the block as it is pulled along its length. By controllingthe vacuum, the cooling of the molten stiffener may be accelerated whileat the same time being supported by the brass block, thereby creating asuperior product shape control process.

One embodiment of a process line 750 for manufacturing fabric cladweatherstrip is depicted in FIG. 11. A foam extruder 752 extrudes thefoam profile 754 using water as a blowing agent onto one or moreconveyers 756 where it obtains its final shape as it cools. A stiffenerextruder 758 extrudes the stiffener 760, which is cooled in a water bath762, while being pulled by a puller 764. Alternatively, an integralstiffener/barb element may be manufactured utilizing a coextruder. Anoptional heating/drying station 766 may be utilized to treat theextruded stiffener 760, depending on the size or shape of the stiffener(e.g., large extrusions may require one or more drying stations). Thefoam 754 and stiffener 760 are joined at a glue table 768, which is fedby a glue machine 770. This combination foam/stiffener element 772 maybe passed through another heating/drying station 774, if desired.

A fabric spool 776 dispenses fabric 778 along the distance traveled bythe combination foam/stiffener element 772. The fabric 778 is notattached to the combination foam/stiffener element 772 at the glue table768, but passes generally above the table 768. As described with regardto FIG. 15C, a small approach angle α; accordingly, the fabric 778travels near to parallel to the combination foam/stiffener element 772until it reaches the fabric guide 776. After forming to the shape of thecombination foam/stiffener element 772, the uncoated weatherstrip passesthrough the coating die 778, which is fed by the coating extruder 780.The finished coated weatherstrip 782 passes through a water bath 784 tocool. An end puller 786 pulls the finished weatherstrip to a reel orcut-up station 790 for final processing.

Fabric clad foam weatherstrip may also be manufactured using ultrasonicwelding in lieu of, or in addition to, the resin coating application.One such ultrasonic welding station 800 is depicted in FIG. 19. In thisembodiment, the foam profile 802 and stiffener 804 have been joined andthe fabric cover layer 806 applied to the foam profile/stiffenercombination. Instead of or in addition to using the coating die(depicted in FIG. 11, for example) to secure the fabric layer 806 to thefoam profile/stiffener combination, one or more ultrasonic welds areutilized to join the various components. In the depicted embodiment, afoam profile 802 secured to a T-shaped stiffener 804 is passed betweentwo steel wheels 808 that guide the stiffener 804 and hold the coverlayer 806 in place. The wheels 808 also press against the stiffener 804and cover layer 806. The stiffener 804 passes over one or moreultrasonic horns 810, which form the weld between the components atlocations 812. Other configurations are possible, depending on whichweatherstrip elements are welded, where the welds are located, etc.Accordingly, an ultrasonic welding station 800 may entirely replace thecoating die station in the process line depicted in FIG. 11.Alternatively, the fabric layer may be secured utilizing continuous orintermittent mechanical fastening systems (staples, stitching, pressurerollers, etc.), thermal fusion, etc. Additional components may beutilized to create a strong bond; for example, a layer of thermallycompatible material may be applied to facilitate a bond generated bythermal fusion. After securing the fabric layer with ultrasonic welding,mechanical systems, fusion, or other forms of attachment, theweatherstrip may either by finished with a complete or partial resincoating, or simply utilized without any resin coating, depending on theapplication. In general, if resin coating is used in addition to anotherform of attachment, the resin coating station could be placed downstreamfrom the alternative attachment station, although certain types ofalternative attachment (e.g., mechanical fastening) may produce asatisfactory product even if installed downstream from the resin coatingstation.

The invention has been described in detail in connection with thepreferred embodiments. These embodiments, however, are merely forexample only and the invention is not limited thereto. It will beappreciated by those skilled in the art that other variations andmodifications can be easily made within the scope of the invention asdefined by the appended claims.

What is claimed is:
 1. A method of making a weatherstrip comprising a foam profile, a stiffener, a resin coating, and a cover layer, the method comprising the steps of: providing a foam profile; providing a stiffener; attaching the stiffener to the foam profile; providing a cover layer, wherein the cover layer comprises a strip with edges; guiding the cover layer into at least one of a desired position, orientation, and contour relative to at least one of the foam profile and the stiffener using an applicator die comprising at least one of a plate forming a shaped opening and a guide; and passing the cover layer, the stiffener, and the foam profile through a resin coating die, wherein the edges of the strip and discrete portions of at least one of the foam profile and the stiffener are coated with resin to anchor the cover layer, while the resin is in a substantially liquid state.
 2. The method of claim 1, further comprising the step of applying the cover layer to at least a portion of the foam profile.
 3. The method of claim 1, further comprising the step of attaching the stiffener to the cover layer.
 4. The method of claim 1, wherein the cover layer comprises a coated side and a reverse side.
 5. The method of claim 4, wherein the reverse cover layer side is disposed proximate to the foam profile.
 6. The method of claim 5, wherein the coated cover layer side and the resin form a bond upon contact.
 7. The method of claim 2, wherein at least a portion of the cover layer is adhered to at least a portion of the foam profile.
 8. The method of claim 1, further comprising the steps of: providing a forming station upstream from the resin coating die; and passing the cover layer through the forming station to preform the cover layer to a shape corresponding to a shape of the foam profile.
 9. A method of making a weatherstrip comprising a foam profile, a resin coating, and a cover layer, the method comprising the steps of: providing a foam profile; providing a cover layer, wherein the cover layer comprises a strip with edges; guiding the cover layer into at least one of a desired position, orientation, and contour relative to the foam profile using an applicator die comprising at least one of a plate forming a shaped opening and a guide; and passing the cover layer and the foam profile through a resin coating die, wherein the edges of the strip and discrete portions of the foam profile are coated with resin to anchor the cover layer, while the resin is in a substantially liquid state.
 10. A method of making a weatherstrip comprising a foam profile, a resin coating, and a cover layer, the method comprising the steps of: providing a foam profile; dispensing a cover layer from a roll, wherein the cover layer comprises a strip with edges; guiding the cover layer into at least one of a desired position, orientation, and contour relative to the foam profile using an applicator die comprising at least one of a plate forming a shaped opening and a guide; and passing the cover layer and the foam profile through a resin coating die, wherein the edges of the strip and discrete portions of the foam profile are coated with resin to anchor the cover layer, while the resin is in a substantially liquid state.
 11. The method of claim 9, further comprising the step of attaching a stiffener to at least one of the foam profile and the cover layer.
 12. The method of claim 11, wherein the passing step further comprises passing the stiffener through the resin coating die.
 13. The method of claim 12, wherein the passing step coats at least a portion of the stiffener with resin.
 14. The method of claim 9, wherein the step of applying the cover layer to the foam profile occurs prior to the passing step.
 15. The method of claim 9, wherein the cover layer is applied to the foam profile with at least one roller.
 16. The method of claim 15, wherein the cover layer is applied to the foam profile while the resin is in a substantially liquid state.
 17. The method of claim 1, wherein the cover layer forms at least one wand.
 18. The method of claim 1, further comprising the step of abrading the cover layer.
 19. A system for manufacturing weatherstrip, the system comprising: a foam profile source; a stiffener source; a cover layer source, wherein the cover layer comprises a strip with edges; a resin source; a device for attaching the stiffener to the foam profile; an applicator die comprising at least one of a plate forming a shaped opening and a guide, wherein the applicator die is for guiding the cover layer into at least one of a desired position, orientation, and contour relative to at least one of the foam profile and the stiffener; and a coating die for receiving the foam profile, the stiffener, and the cover layer and for coating the edges of the cover layer and at least one of the foam profile and the stiffener with resin to anchor the cover layer.
 20. A method of making a weatherstrip comprising a cover layer and at least one of a foam profile and a stiffener, the method comprising the steps of: providing the cover layer, wherein the cover layer comprises a strip with edges; providing at least one of the foam profile and the stiffener; applying at least a portion of the cover layer to the at least one of the foam profile and the stiffener to create a combined component, wherein the cover layer is applied using at least one of (i) an applicator die comprising at least one of a plate forming a shaped opening and a guide, and (ii) a plurality of wheels; and passing the combined component through an ultrasonic welding station, thereby securing the edges of the cover layer to the at least one of the foam profile and the stiffener.
 21. The method of claim 1, wherein the cover layer comprises at least one of a woven and a non-woven fabric.
 22. The method of claim 1, wherein the cover layer comprises polypropylene.
 23. The method of claim 21, wherein the fabric cover layer further comprises a film.
 24. The method of claim 9, wherein the cover layer further comprises raised ribs.
 25. The method of claim 9, further comprising the step of passing the foam profile and cover layer through a second resin coating die, wherein at least a portion of the cover layer is coated with a second resin so as to form at least one rib, while the second resin is in a substantially liquid state.
 26. The method of claim 9, further comprising the step of applying the cover layer to at least a portion of the foam profile.
 27. A method of making a weatherstrip comprising a foam profile, a resin coating, and a cover layer, the method comprising the steps of: providing a foam profile; guiding a cover layer into at least one of a desired position, orientation, and contour relative to at least a portion of the foam profile using an applicator die comprising at least one of a plate forming a shaped opening and a guide, wherein the cover layer is from a roll and comprises a strip with edges; and passing the cover layer and the foam profile through a resin coating die, wherein the edges of the strip and discrete portions of the foam profile are coated with resin to anchor the cover layer, while the resin is in a substantially liquid state.
 28. The method of claim 10, wherein the portion of the foam profile to which the cover layer is applied is coated with the resin.
 29. The system of claim 19, wherein the coating die is adapted to cover the edges of the strip with resin.
 30. The system of claim 19, wherein the coating die is adapted to cover completely a coated side of the strip with resin.
 31. The system of claim 19, wherein the cover layer comprises at least two separate strips.
 32. The system of claim 31, wherein the coating die is adapted to cover completely the coated sides of the two strips with resin.
 33. The system of claim 19, wherein the cover layer comprises an adhesive layer on the strip.
 34. The system of claim 19, wherein the cover layer comprises a scuffed surface.
 35. The system of claim 19, wherein the coating die is adapted to leave at least a portion of the foam profile and the stiffener uncoated.
 36. The system of claim 19, wherein the coating die is adapted to place the cover layer over the resin.
 37. The system of claim 19, wherein the cover layer comprises at least one rib.
 38. The system of claim 37, wherein the at least one rib comprises a coating.
 39. The system of claim 19, wherein the cover layer forms at least one wand.
 40. The system of claim 19, wherein the resin overlaps the edges from about 0.03 inches to about 0.06 inches. 